Download Yamaha FZS1000S Owner`s manual

OWNER’S MANUAL
FZS1000N
FZS1000NC
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2001 . 1 - 2.3 × 3 CR
(E)
LIT-11626-14-48
5LV-28199-10
EAU03438
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
EAU00002
INTRODUCTION
Congratulations on your purchase of the Yamaha FZS1000. This model is the result
of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability
that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic
maintenance of this motorcycle. If you have any questions concerning the operation
or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met
these standards without reducing the performance or economy of operation of the
motorcycle. To maintain these high standards, it is important that you and your
Yamaha dealer pay close attention to the recommended maintenance schedules and
operating instructions contained within this manual.
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
WARNING
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while
this manual contains the most current product information available at the time of printing,
there may be minor discrepancies between your motorcycle and this manual. If you have
any questions concerning this manual, please consult your Yamaha dealer.
_
_
EAU00003
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IMPORTANT MANUAL INFORMATION
EW000000
WARNING
PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING
TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES
AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
_
_
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IMPORTANT MANUAL INFORMATION
AFFIX DEALER
LABEL HERE
EAU03336
FZS1000N/FZS1000NC
OWNER’S MANUAL
© 2001 by Yamaha Motor Corporation, U.S.A.
1st Edition, January 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-14-48
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
TABLE OF CONTENTS
EAU00009
1 SAFETY INFORMATION
1
2 DESCRIPTION
2
3 INSTRUMENT AND CONTROL FUNCTIONS
3
4 PRE-OPERATION CHECKS
4
5 OPERATION AND IMPORTANT RIDING POINTS
5
6 PERIODIC MAINTENANCE AND MINOR REPAIR
6
7 MOTORCYCLE CARE AND STORAGE
7
8 SPECIFICATIONS
8
9 CONSUMER INFORMATION
9
INDEX
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SAFETY INFORMATION
Safe riding .......................................................................................... 1-1
Protective apparel .............................................................................. 1-3
Modifications ...................................................................................... 1-3
Loading and accessories ................................................................... 1-3
Gasoline and exhaust gas.................................................................. 1-5
Location of important labels .............................................................. 1-7
1
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SAFETY INFORMATION
EAU00014
1-
1
2
3
4
5
6
7
8
9
MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE
DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE
OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S
MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
Safe riding
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. This motorcycle is designed to carry the operator and a passenger.
3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of
automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who
did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the
chance of this type of accident.
Therefore:
a. Wear a brightly colored jacket.
b. Use extra caution when you are approaching and passing through intersections, since intersections are the most likely places for motorcycle accidents to occur.
c. Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.
1-1
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SAFETY INFORMATION
4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in
accidents do not even have a current motorcycle license.
a. Make sure that you are qualified and that you only lend your motorcycle to other qualified
operators.
b. Know your skills and limits. Staying within your limits may help you to avoid an accident.
c. We recommend that you practice riding your motorcycle where there is no traffic until you have
become thoroughly familiar with the motorcycle and all of its controls.
5. Many accidents have been caused by error of the motorcycle operator. A typical error made by the
operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean
angle for the speed).
a. Always obey the speed limit and never travel faster than warranted by road and traffic conditions.
b. Always signal before turning or changing lanes. Make sure that other motorists can see you.
6. The posture of the operator and passenger is important for proper control.
a. The operator should keep both hands on the handlebar and both feet on the operator footrests
during operation to maintain control of the motorcycle.
b. The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with
both hands and keep both feet on the passenger footrests.
c. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.
7. Never ride under the influence of alcohol or other drugs.
8. This motorcycle is designed for on-road use only. It is not suitable for off-road use.
1
2
3
4
5
6
7
8
9
1-2
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SAFETY INFORMATION
Protective apparel
1
2
3
4
5
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety
helmet is the single most critical factor in the prevention or reduction of head injuries.
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard.
3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.
4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels
and cause injury or an accident.
5. Never touch the engine or exhaust system during or after operation. They become very hot and can
cause burns. Always wear protective clothing that covers your legs, ankles, and feet.
6. A passenger should also observe the above precautions.
6
Modifications
7
Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment,
may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may
also make your motorcycle illegal to use.
8
Loading and accessories
9
Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the
weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme
caution when adding cargo or accessories to your motorcycle. Use extra care when riding a
motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading
cargo or adding accessories to your motorcycle:
1-3
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SAFETY INFORMATION
Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maximum
load limit of FZS1000: 189 kg (417 lb) / FZS1000C: 188 kg (415 lb). When loading within this weight
limit, keep the following in mind:
1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make
sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.
2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely
attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.
3. Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such items as sleeping bags, duffel bags, or tents, can create unstable handling or a slow
steering response.
1
2
3
4
5
Accessories
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since
Yamaha cannot test all other accessories that may be available, you must personally be responsible
for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when
selecting and installing any accessories.
Keep the following guidelines in mind, as well as those provided under “Loading” when mounting accessories.
1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground
clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors.
1-4
6
7
8
9
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SAFETY INFORMATION
1
2
3
4
5
6
7
8
9
a. Accessories fitted to the handlebar or the front fork area can create instability due to improper
weight distribution or aerodynamic changes. If accessories are added to the handlebar or front
fork area, they must be as lightweight as possible and should be kept to a minimum.
b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic
effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross
winds. These accessories may also cause instability when passing or being passed by large
vehicles.
c. Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore,
such accessories are not recommended.
2. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the
motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas
1. GASOLINE IS HIGHLY FLAMMABLE:
a. Always turn the engine off when refueling.
b. Take care not to spill any gasoline on the engine or exhaust system when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your
motorcycle in an area that has adequate ventilation.
3. Always turn the engine off before leaving the motorcycle unattended and remove the key from the
main switch. When parking the motorcycle, note the following:
1-5
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SAFETY INFORMATION
a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas.
b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.
c. Do not park the motorcycle near a flammable source (e.g., a kerosene heater, or near an open
flame), otherwise it could catch fire.
4. When transporting the motorcycle in another vehicle, make sure that it is kept upright. If the motorcycle should lean over, gasoline may leak out of the carburetor or fuel tank.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your
eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash
the affected area with soap and water and change your clothes.
1
2
3
4
5
6
7
8
9
1-6
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SAFETY INFORMATION
EAU02977
Location of important labels
Please read the following important labels carefully before operating this motorcycle.
1
2
3
4
5
6
7
8
9
1-7
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SAFETY INFORMATION
1
5
California only
1
2
3
2
4
6
5
6
3
7
8
7
4
1-8
9
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DESCRIPTION
Left view ............................................................................................. 2-1
Right view........................................................................................... 2-2
Controls and instruments ................................................................... 2-3
2
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DESCRIPTION
EAU00026
2-
Left view
2
1. Front fork compression damping
force adjusting screw
2. Front fork rebound damping force
adjusting screw
3. Front fork spring preload adjusting
bolt
4. Air filter element
5. Fuses
6. Storage compartment
7. Grab bar
8. Seat lock/helmet holder
9. Shock absorber assembly
compression damping force
adjusting screw
10. Shock absorber assembly spring
preload adjusting ring
11. Shock absorber assembly rebound
damping force adjusting knob
12. Shift pedal
(page 3-13)
(page 3-12)
(page 3-12)
(page 6-19)
(page 6-38)
(page 3-11)
2-1
(page 3-10)
(page 3-14)
(page 3-14)
(page 3-14)
(page 3-6)
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DESCRIPTION
Right view
2
13. Owner’s tool kit
14. Rear brake fluid reservoir
15. Battery
16. Front brake fluid reservoir
17. Radiator cap
18. Engine oil filter cartridge
19. Engine oil level check window
20. Brake pedal
21. Coolant reservoir
(page 6-1)
(page 6-30)
(page 6-37)
(page 6-29)
(page 6-17)
2-2
(page 6-12)
(page 6-12)
(page 3-7)
(page 6-15)
U5LV10.book Page 3 Wednesday, October 23, 2002 2:45 PM
DESCRIPTION
Controls and instruments
2
1. Clutch lever
2. Left handlebar switches
3. Starter (choke) lever
4. Speedometer unit
5. Main switch/steering lock
6. Tachometer unit
7. Fuel gauge
8. Right handlebar switches
9. Brake lever
10. Throttle grip
(page 3-6)
(page 3-5)
(page 3-9)
(page 3-3)
(page 3-1)
2-3
(page 3-3)
(page 3-5)
(page 3-6)
(page 3-7)
(page 6-22)
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock .................................................................. 3-1
Indicator and warning lights ............................................................. 3-2
Speedometer unit .............................................................................. 3-3
Tachometer unit ................................................................................. 3-3
Self-diagnosis devices ....................................................................... 3-4
Fuel gauge ........................................................................................ 3-5
Handlebar switches ........................................................................... 3-5
Clutch lever ....................................................................................... 3-6
Shift pedal ......................................................................................... 3-6
Brake lever ........................................................................................ 3-7
Brake pedal ....................................................................................... 3-7
Fuel tank cap ..................................................................................... 3-7
Fuel ................................................................................................... 3-8
Starter (choke) lever .......................................................................... 3-9
Seat ................................................................................................. 3-10
Helmet holder .................................................................................. 3-10
Storage compartment ..................................................................... 3-11
Adjusting the front fork .................................................................... 3-11
Adjusting the shock absorber assembly .......................................... 3-13
EXUP system .................................................................................. 3-15
Sidestand ........................................................................................ 3-16
Ignition circuit cut-off system ........................................................... 3-17
3
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU00027
3-
3
EAU00029
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU00032
ON
All electrical systems are supplied with
power, and the headlight, meter lighting, taillight and position lights come
on, and the engine can be started. The
key cannot be removed.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
EAU00040
LOCK
The steering is locked, and all electrical
systems are off. The key can be
removed.
To lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” position, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.
To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
3-1
1. Push.
2. Turn.
EW000016
WARNING
Never turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the motorcycle is stopped before turning the
key to “OFF” or “LOCK”.
_
_
U5LV10.book Page 2 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU00063
EAU01716
High beam indicator light “
”
This indicator light comes on when the
high beam of the headlight is switched
on.
Coolant temperature warning light
“
”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and allow
the engine to cool.
EAU03285
1.
2.
3.
4.
5.
6.
7.
Left turn signal indicator light “
”
Neutral indicator light “ ”
High beam indicator light “
”
Oil level warning light “
”
Right turn signal indicator light “
”
Coolant temperature warning light “
Fuel level warning light “ ”
”
EAU03034
Indicator and warning lights
EAU03299*
Turn signal indicator lights
“
” and “
”
The corresponding indicator light flashes when the turn signal switch is
pushed to the left or right.
Oil level warning light “
”
This warning light comes on when the
engine oil level is low.
The electrical circuit of the warning light
can be checked according to the following procedure.
1. Turn the key to “ON”.
2. If the warning light does not come
on, have a Yamaha dealer check
the electrical circuit.
NOTE:
Even if the oil level is sufficient, the
warning light may flicker when riding on
a slope or during sudden acceleration
or deceleration, but this is not a malfunction.
_
_
EAU00061
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
3-2
EC000002
CAUTION:
Do not operate the engine if it is
overheated.
_
_
EAU03965
Fuel level warning light “ ”
This warning light comes on when the
fuel level drops below approximately
4 L (0.9 Imp gal, 1.1 US gal). When this
occurs, refuel as soon as possible.
The electrical circuit of the warning light
can be checked according to the following procedure.
1. Turn the key to “ON”.
2. If the warning light does not come
on, have a Yamaha dealer check
the electrical circuit.
3
U5LV10.book Page 3 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
To set a mode
Push the “SELECT” button to change
between the odometer mode “ODO”,
and the tripmeter modes “TRIP 1” and
“TRIP 2” in the following order:
ODO → TRIP 1 → TRIP 2 → ODO
To reset a meter
To reset either tripmeter 1 or 2 to 0.0,
select either by pushing the “SELECT”
button, and then push the “RESET”
button for at least one second.
3
1.
2.
3.
4.
Speedometer
Odometer/tripmeter
“SELECT” button
“RESET” button
1. Tachometer
2. Tachometer red zone
3. Clock
EAU03954
Tachometer unit
EAU03953
Speedometer unit
The electric tachometer allows the rider
to monitor the engine speed and keep it
within the ideal power range.
The speedometer unit is equipped with
the following:
● an odometer
● two tripmeters
When set to “ODO”, the motorcycle’s
total mileage is indicated.
When set to “TRIP 1” or “TRIP 2”, the
motorcycle’s mileage since the tripmeter was last reset is indicated. Use the
tripmeters to estimate how far you can
ride on a tank of fuel. This information
will enable you to plan fuel stops in the
future.
EC000003
CAUTION:
Do not operate the engine in the tachometer red zone.
Red zone: 11,500 r/min and above
_
_
This tachometer unit is equipped with a
clock.
3-3
U5LV10.book Page 4 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
To set the clock:
1. Push both the “SELECT” and
“RESET” buttons for at least two
seconds.
2. When the hour digits start flashing,
push the “RESET” button to set
the hours.
3. Push the “SELECT” button to
change the minutes.
4. When the minute digits start flashing, push the “RESET” button to
set the minutes.
5. Push the “SELECT” button to start
the clock.
NOTE:
After setting the clock, be sure to push
the “SELECT” button before turning the
key to “OFF”, otherwise the clock will
not be set.
EAU04049*
Self-diagnosis devices
This model is equipped with a self-diagnosis device for the following electrical circuits:
● throttle position sensor
● speed sensor
● EXUP system
● overturn switch
If any of those circuits are defective,
the tachometer will repeatedly display
the following error code:
CB-23E
0 r/min for
3 seconds
_
_
Circuit-specific
number of r/min
for 2.5 seconds
(See the table
below.)
Current
engine
speed for
3 seconds
Use the chart below to identify the
faulty electrical circuit.
CB-29E
Specific r/min
Faulty electrical circuit
3,000 r/min
Throttle position sensor
4,000 r/min
Speed sensor
7,000 r/min
EXUP system
9,000 r/min
Overturn switch
3-4
If the tachometer displays such an error code, note the circuit-specific number of r/min, and then have a Yamaha
dealer check the motorcycle.
EC000004
CAUTION:
When the tachometer displays an
error code, the motorcycle should
be checked as soon as possible in
order to avoid engine damage.
_
_
3
U5LV10.book Page 5 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU03889
Turn signal switch “
/
”
To signal a right-hand turn, push this
switch to “
”. To signal a left-hand
turn, push this switch to “
”. When
released, the switch returns to the center position. To cancel the turn signal
lights, push the switch in after it has returned to the center position.
3
1. Fuel gauge
EAU00110
Fuel gauge
The fuel gauge indicates the amount of
fuel in the fuel tank. The needle moves
towards “E” (Empty) as the fuel level
decreases. When the needle reaches
“E”, approximately 4 L (0.9 Imp gal,
1.1 US gal) of fuel remain in the fuel
tank. If this occurs, refuel as soon as
possible.
1. Dimmer switch “
/
2. Turn signal switch “
3. Horn switch “
”
”
/
”
EAU00129
EAU00118
Handlebar switches
EAU03888
Dimmer switch “
/
”
Set this switch to “
” for the high
beam and to “
” for the low beam.
NOTE:
Do not allow the fuel tank to empty itself completely.
_
_
3-5
Horn switch “
”
Press this switch to sound the horn.
U5LV10.book Page 6 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Engine stop switch “
2. Start switch “
”
/
”
1. Clutch lever
1. Shift pedal
EAU00152
EAU03890
Engine stop switch “ / ”
Set this switch to “ ” before starting
the engine. Set this switch to “ ” to
stop the engine in case of an emergency, such as when the motorcycle overturns or when the throttle cable is
stuck.
EAU00143
Start switch “ ”
Push this switch to crank the engine
with the starter.
EC000005
EAU00157
Clutch lever
Shift pedal
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handlebar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the ignition
circuit cut-off system. (See page 3-17
for an explanation of the ignition circuit
cut-off system.)
The shift pedal is located on the left
side of the engine and is used in combination with the clutch lever when
shifting the gears of the 6-speed constant-mesh transmission equipped on
this motorcycle.
CAUTION:
See page 5-1 for starting instructions prior to starting the engine.
_
_
3-6
U5LV10.book Page 7 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
3
1.
2.
3.
a.
Brake lever
Brake lever position adjusting dial
Arrow mark
Distance between brake lever and handlebar
grip
EAU00161
Brake lever
1. Brake pedal
EAU00162
Brake pedal
1. Fuel tank cap lock cover
2. Unlock.
EAU02935
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
The brake lever is located at the right
handlebar grip. To apply the front brake,
pull the lever toward the handlebar grip.
The brake lever is equipped with a position adjusting dial. To adjust the distance between the brake lever and the
handlebar grip, turn the adjusting dial
while holding the lever pushed away
from the handlebar grip. Make sure that
the appropriate setting on the adjusting
dial is aligned with the arrow mark on
the brake lever.
Fuel tank cap
To open the fuel tank cap
Open the fuel tank cap lock cover, insert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be
opened.
To close the fuel tank cap
1. Push the fuel tank cap into position with the key inserted in the
lock.
3-7
U5LV10.book Page 8 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
EAU00185
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfaces or plastic parts.
_
NOTE:
The fuel tank cap cannot be closed unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked.
_
_
EWA00025
WARNING
Make sure that the fuel tank cap is
properly closed before riding.
_
3
1. Fuel tank filler tube
2. Fuel level
_
_
EAU03753
Fuel
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
EW000130
_
WARNING
● Do not overfill the fuel tank, otherwise it may overflow when the
fuel warms up and expands.
● Avoid spilling fuel on the hot
engine.
_
3-8
U5LV10.book Page 9 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU00189
3
Recommended fuel:
UNLEADED FUEL
Fuel tank capacity:
Total amount:
21 L (4.6 Imp gal, 5.5 US gal)
Reserve amount:
4 L (0.9 Imp gal, 1.1 US gal)
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number
[(R+M)/2] of 86 or higher, or a research
octane number of 91 or higher. If
knocking (or pinging) occurs, use a
gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs. If unleaded gasoline is not available, then leaded regular gasoline can be used.
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing
ethanol can be used if the ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by Yamaha because it can
cause damage to the fuel system or vehicle performance problems.
1. Starter (choke) lever “
”
EAU03839
Starter (choke) lever “
”
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the lever in direction a to turn on
the starter (choke).
Move the lever in direction b to turn off
the starter (choke).
3-9
U5LV10.book Page 10 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Seat lock
2. Unlock.
1. Projection
2. Seat holder
EAU03956
Seat
To remove the seat
1. Insert the key into the seat lock,
and then turn it clockwise.
2. While holding the key in that position, lift the rear of the seat, and
then pull the seat off.
1. Helmet holder
2. Unlock.
To install the seat
1. Insert the projection on the front of
the seat into the seat holder as
shown.
2. Push the rear of the seat down to
lock it in place.
3. Remove the key.
NOTE:
Make sure that the seat is properly secured before riding.
EAU00261
Helmet holder
To open the helmet holder, insert the
key into the lock, and then turn the key
as shown.
To lock the helmet holder, turn the key
to the original position, and then remove it.
EW000030
_
_
WARNING
Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of
control and possibly an accident.
_
_
3-10
U5LV10.book Page 11 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
When storing the owner’s manual or
other documents in the storage compartment, be sure to wrap them in a
plastic bag so that they will not get wet.
When washing the motorcycle, be
careful not to let any water enter the
storage compartment.
EAU04002
Adjusting the front fork
This front fork is equipped with spring
preload adjusting bolts, rebound damping force adjusting screws and compression damping force adjusting
screws.
EW000035
3
WARNING
Always adjust both fork legs equally, otherwise poor handling and loss
of stability may result.
_
1. Storage compartment
EAU04101
Storage compartment
The storage compartment is located
under the seat. (See page 3-10 for seat
removal and installation procedures.)
_
EWA00005
_
WARNING
Do not exceed the load limit of
3 kg (7 lb) for the storage compartment.
● Do not exceed the maximum
load of 189 kg (417 lb) for the
vehicle.
●
_
3-11
U5LV10.book Page 12 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Spring preload adjusting bolt
Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting bolt on each fork leg in direction a. To decrease the spring preload
and
thereby
soften
the
suspension, turn the adjusting bolt on
each fork leg in direction b.
1. Current setting
2. Front fork cap bolt
1. Rebound damping force adjusting screw
NOTE:
Align the appropriate groove on the adjusting mechanism with the top of the
front fork cap bolt.
_
_
CI-12E
Setting
Minimum (soft)
5*
Standard
2
Maximum (hard)
1
* fully turned out position
Rebound damping force
To increase the rebound damping
force and thereby harden the rebound
damping, turn the adjusting screw on
each fork leg in direction a. To decrease the rebound damping force and
thereby soften the rebound damping,
turn the adjusting screw on each fork
leg in direction b.
CI-02E
Minimum (soft)
17 clicks in direction b*
Standard
7 clicks in direction b*
Maximum (hard)
1 click in direction b*
* With the adjusting screw fully turned in direction a
3-12
U5LV10.book Page 13 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
EC000015
CAUTION:
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.
_
_
NOTE:
Although the total number of clicks of a
damping force adjusting mechanism
may not exactly match the above specifications due to small differences in
production, the actual number of clicks
always represents the entire adjusting
range. To obtain a precise adjustment,
it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the
specifications as necessary.
_
3
1. Compression damping force adjusting screw
Compression damping force
To increase the compression damping
force and thereby harden the compression damping, turn the adjusting screw
on each fork leg in direction a. To decrease the compression damping force
and thereby soften the compression
damping, turn the adjusting screw on
each fork leg in direction b.
_
CI-02E
Minimum (soft)
21 clicks in direction b*
Standard
6 clicks in direction b*
Maximum (hard)
1 click in direction b*
* With the adjusting screw fully turned in direction a
3-13
EAU01699
Adjusting the shock absorber
assembly
This shock absorber assembly is
equipped with a spring preload adjusting ring, a rebound damping force adjusting knob and a compression
damping force adjusting screw.
EC000015
CAUTION:
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.
_
_
U5LV10.book Page 14 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Spring preload adjusting ring
2. Special wrench
Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction a. To decrease the spring preload and thereby
soften the suspension, turn the adjusting ring in direction b.
CI-10E
Minimum (soft)
1. Rebound damping force adjusting knob
1. Compression damping force adjusting screw
Rebound damping force
To increase the rebound damping
force and thereby harden the rebound
damping, turn the adjusting knob in direction a. To decrease the rebound
damping force and thereby soften the
rebound damping, turn the adjusting
knob in direction b.
Compression damping force
To increase the compression damping
force and thereby harden the compression damping, turn the adjusting screw
in direction a. To decrease the compression damping force and thereby
soften the compression damping, turn
the adjusting screw in direction b.
CI-03E
CI-02E
Setting
Minimum (soft)
20 clicks in direction b*
Minimum (soft)
1 click in direction a*
1
Standard
10 clicks in direction b*
Standard
7 clicks in direction a*
Maximum (hard)
3 clicks in direction b*
Maximum (hard)
12 clicks in direction a*
Standard
6
Maximum (hard)
11
* With the adjusting knob fully turned in direction a
3-14
* With the adjusting screw fully turned in direction b
U5LV10.book Page 15 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
NOTE:
Although the total number of clicks of a
damping force adjusting mechanism
may not exactly match the above specifications due to small differences in
production, the actual number of clicks
always represents the entire adjusting
range. To obtain a precise adjustment,
it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the
specifications as necessary.
EAU00315
_
3
_
WARNING
This shock absorber contains highly pressurized nitrogen gas. For
proper handling, read and understand the following information before handling the shock absorber.
The manufacturer cannot be held responsible for property damage or
personal injury that may result from
improper handling.
● Do not tamper with or attempt to
open the gas cylinder.
● Do not subject the shock absorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
● Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping performance.
● Always have a Yamaha dealer
service the shock absorber.
_
_
3-15
EAU01571
EXUP system
This motorcycle is equipped with
Yamaha’s EXUP (EXhaust Ultimate
Power valve) system. This system
boosts engine power by means of a
valve that regulates the diameter of the
exhaust pipe. The EXUP system valve
is constantly adjusted in accordance
with the engine speed by a computercontrolled servomotor.
EC000027
_
_
CAUTION:
● The EXUP system has been set
and extensively tested at the
Yamaha factory. Changing
these settings without sufficient
technical knowledge may result
in poor performance of or damage to the engine.
● If the EXUP system does not operate, have a Yamaha dealer
check it.
U5LV10.book Page 16 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU00330
Sidestand
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)
_
_
EW000044
WARNING
The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up), otherwise the sidestand could contact
the ground and distract the operator, resulting in a possible loss of
control. Yamaha’s ignition circuit
cut-off system has been designed to
assist the operator in fulfilling the
responsibility of raising the sidestand before starting off. Therefore,
check this system regularly as described below and have a Yamaha
dealer repair it if it does not function
properly.
_
_
3-16
3
U5LV10.book Page 17 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU03741
EW000046
Ignition circuit cut-off system
3
The ignition circuit cut-off system (comprising the sidestand switch, clutch
switch and neutral switch) has the following functions.
● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is
not pulled.
● It prevents starting when the transmission is in gear and the clutch
lever is pulled, but the sidestand is
still down.
● It cuts the running engine when
the transmission is in gear and the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
_
WARNING
● The vehicle must be placed on
the centerstand during this inspection.
● If a malfunction is noted, have a
Yamaha dealer check the system before riding.
_
3-17
U5LV10.book Page 18 Wednesday, October 23, 2002 2:45 PM
INSTRUMENT AND CONTROL FUNCTIONS
CD-01E
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
YES
NOTE:
This check is most reliable if performed with
a warmed-up engine.
”.
NO
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
YES
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
YES
The system is OK. The motorcycle can be ridden.
3-18
3
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
PRE-OPERATION CHECKS
Pre-operation check list ..................................................................... 4-1
4
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
PRE-OPERATION CHECKS
EAU01114
4-
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
ITEM
CHECKS
PAGE
Fuel
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
Engine oil
• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
Coolant
• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.
6-15–6-16
Front brake
•
•
•
•
•
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
6-29–6-30
Rear brake
•
•
•
•
•
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
6-27–6-30
Clutch
•
•
•
•
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
4
3-8–3-9
6-12
6-27
4-1
U5LV10.book Page 2 Wednesday, October 23, 2002 2:45 PM
PRE-OPERATION CHECKS
ITEM
CHECKS
Make sure that operation is smooth.
Lubricate throttle grip, housing and cables if necessary.
Check free play.
If necessary, have Yamaha dealer make adjustment.
PAGE
Throttle grip
•
•
•
•
Control cables
• Make sure that operation is smooth.
• Lubricate if necessary.
6-33
Drive chain
•
•
•
•
Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.
6-31
Wheels and tires
•
•
•
•
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
Brake and shift pedals
• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.
6-33
Brake and clutch levers
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
6-33
Centerstand, sidestand
• Make sure that operation is smooth.
• Lubricate pivots if necessary.
6-34
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
—
Instruments, lights, signals
and switches
• Check operation.
• Correct if necessary.
—
Sidestand switch
• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.
4-2
6-22
6-23–6-26
3-16
4
U5LV10.book Page 3 Wednesday, October 23, 2002 2:45 PM
PRE-OPERATION CHECKS
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
_
_
EWA00033
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle.
_
_
4
4-3
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
OPERATION AND IMPORTANT RIDING POINTS
Starting and warming up a cold engine ............................................. 5-1
Starting a warm engine ..................................................................... 5-3
Shifting .............................................................................................. 5-3
Engine break-in ................................................................................. 5-5
Parking .............................................................................................. 5-6
5
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
OPERATION AND IMPORTANT RIDING POINTS
EAU00372
5-
_
5
EAU00373
EAU00376
WARNING
● Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer regarding any control or function
that you do not thoroughly
understand.
● Never start the engine or operate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of consciousness and death within a
short time. Always make sure
that there is adequate ventilation.
● Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised completely, it could contact the
ground and distract the operator, resulting in a possible loss
of control.
CAUTION:
● Make sure not to store personal
items near the air cleaner intake, otherwise air intake will be
blocked and performance will
suffer.
● Make sure not to put anything
near the battery and its terminals, otherwise electrical failure
and acid corrosion may result.
_
EAU01164*
Starting and warming up a
cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
● The transmission is in the neutral
position.
● The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
_
_
WARNING
Before starting the engine,
check the function of the ignition circuit cut-off system according to the procedure
described on page 3-18.
● Never ride with the sidestand
down.
●
_
_
5-1
U5LV10.book Page 2 Wednesday, October 23, 2002 2:45 PM
OPERATION AND IMPORTANT RIDING POINTS
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
EC000035
CAUTION:
If the fuel level warning light comes
on, check the fuel level, and, if necessary, refuel as soon as possible.
_
turned to “ON”, the warning
light does not come on for a few
seconds, then go off, or if it
does not go off after starting
with sufficient engine oil, have a
Yamaha dealer check the electrical circuit.
● If the fuel level warning light remains on after starting, stop the
engine, and then check the fuel
level. If necessary, refuel as
soon as possible, and then
check the warning light again.
If, when the key is turned to
“ON”, the warning light does
not come on for a few seconds,
then go off, or if it does not go
off after starting with sufficient
fuel, have a Yamaha dealer
check the electrical circuit.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one
attempt.
_
_
_
2. Shift the transmission into the neutral position.
_
NOTE:
When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.
_
_
3. Turn the starter (choke) on and
completely close the throttle. (See
page 3-9 for starter (choke) operation.)
4. Start the engine by pushing the
start switch.
CAUTION:
● The oil level warning light, coolant temperature warning light
and fuel level warning light
should come on for a few seconds, then go off. If a warning
light does not go off, have a
Yamaha dealer check the electrical circuit.
● If the oil level warning light flickers or remains on after starting,
immediately stop the engine,
and then check the engine oil
level and the vehicle for oil leakage. If necessary, add engine
oil, and then check the warning
light again. If, when the key is
5-2
_
5. After starting the engine, move the
starter (choke) lever back halfway.
5
U5LV10.book Page 3 Wednesday, October 23, 2002 2:45 PM
OPERATION AND IMPORTANT RIDING POINTS
ECA00055
CAUTION:
For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!
_
EAU01258
Starting a warm engine
Follow the same procedure as for starting a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
_
6. When the engine is warm, turn the
starter (choke) off.
1. Shift pedal
N. Neutral position
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off. To avoid the possibility of excessive exhaust emissions,
never leave the starter (choke) on longer than necessary. The time necessary
for starter (choke) use depends upon
the ambient temperature. Temperatures above 10 °C (50 °F) require about
10 seconds of starter (choke) use and
temperatures below 10 °C (50 °F) require about 3.5 seconds with the starter
(choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position.
_
5
EAU00423
Shifting
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the
illustration.
NOTE:
To shift the transmission into the neutral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
_
_
_
5-3
U5LV10.book Page 4 Wednesday, October 23, 2002 2:45 PM
OPERATION AND IMPORTANT RIDING POINTS
EC000048
_
_
CAUTION:
● Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long distances. The transmission is
properly lubricated only when
the engine is running. Inadequate lubrication may damage
the transmission.
● Always use the clutch while
changing gears to avoid damaging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU02988
EAU00427
To start out and accelerate
1. Pull the clutch lever to disengage
the clutch.
2. Shift the transmission into first
gear. The neutral indicator light
should go out.
3. Open the throttle gradually, and at
the same time, release the clutch
lever slowly.
4. At the recommended shift points
shown in the table on page 5-5,
close the throttle, and at the same
time, quickly pull the clutch lever
in.
5. Shift the transmission into second
gear. (Make sure not to shift the
transmission into the neutral position.)
6. Open the throttle part way and
gradually release the clutch lever.
7. Follow the same procedure when
shifting to the next higher gear.
To decelerate
1. Apply both the front and the rear
brakes to slow the motorcycle.
2. Shift the transmission into first
gear when the motorcycle reaches
25 km/h (15.5 mi/h). If the engine
is about to stall or runs very roughly, pull the clutch lever in and use
the brakes to stop the motorcycle.
3. Shift the transmission into the neutral position when the motorcycle
is almost completely stopped. The
neutral indicator light should come
on.
NOTE:
Always shift gears at the recommended shift points.
_
_
5-4
5
U5LV10.book Page 5 Wednesday, October 23, 2002 2:45 PM
OPERATION AND IMPORTANT RIDING POINTS
EAU01128
EAU02989
Recommended shift points
The recommended shift points during
acceleration and deceleration are
shown in the table below.
CF-05E
1st
2nd
3rd
4th
5th
5
→
→
→
→
→
2nd
3rd
4th
5th
6th
Acceleration
shift point
km/h (mi/h)
Deceleration
shift point
km/h (mi/h)
16 (9.9)
24 (14.9)
32 (19.9)
40 (24.9)
48 (29.8)
–
25 (15.5)
25 (15.5)
25 (15.5)
25 (15.5)
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1,600 km (1,000 mi).
For this reason, you should read the
following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,600 km (1,000 mi). The various parts
in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided.
EAU03749*
0–1,000 km (0–600 mi)
Avoid prolonged operation
5,000 r/min.
above
1,000–1,600 km (600–1,000 mi)
Avoid prolonged operation above
6,000 r/min.
EC000052*
CAUTION:
After 1,000 km (600 mi) of operation,
the engine oil must be changed and
the oil filter cartridge replaced.
_
_
1,600 km (1,000 mi) and beyond
The vehicle can now be operated
normally.
EC000053
_
_
5-5
CAUTION:
● Keep the engine speed out of
the tachometer red zone.
● If any engine trouble should occur during the engine break-in
period, immediately have a
Yamaha dealer check the vehicle.
U5LV10.book Page 6 Wednesday, October 23, 2002 2:45 PM
OPERATION AND IMPORTANT RIDING POINTS
EAU00460
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
_
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them.
● Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
●
5
_
5-6
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Periodic maintenance ..........................................6-1
Owner’s tool kit ....................................................6-1
Periodic maintenance chart for the emission
control system ...................................................6-3
General maintenance and lubrication chart .........6-5
Removing and installing panels ...........................6-8
Checking the spark plugs ..................................6-10
Canister (for California only) ..............................6-11
Engine oil and oil filter cartridge ........................6-12
Coolant ..............................................................6-15
Cleaning the air filter element ............................6-19
Adjusting the carburetors ...................................6-21
Adjusting the throttle cable free play ..................6-22
Adjusting the valve clearance ............................6-22
Tires ...................................................................6-23
Cast wheels .......................................................6-26
Accessories and replacement parts ..................6-26
Adjusting the clutch lever free play ....................6-27
Adjusting the brake pedal position .....................6-27
Adjusting the rear brake light switch ..................6-28
Checking the front and rear brake pads .............6-29
Checking the brake fluid level ............................6-29
Changing the brake fluid ....................................6-30
Drive chain slack ............................................... 6-31
Lubricating the drive chain ................................ 6-32
Checking and lubricating the cables ................. 6-33
Checking and lubricating the brake and
shift pedals ...................................................... 6-33
Checking and lubricating the brake and
clutch levers .................................................... 6-33
Checking and lubricating the centerstand and
sidestand ......................................................... 6-34
Lubricating the rear suspension ........................ 6-34
Checking the front fork ...................................... 6-35
Checking the steering ....................................... 6-35
Checking the wheel bearings ............................ 6-36
Battery ............................................................... 6-37
Replacing the fuses .......................................... 6-38
Replacing a headlight bulb ................................ 6-39
Replacing a tail/brake light bulb ........................ 6-41
Replacing a turn signal light bulb ...................... 6-41
Front wheel ....................................................... 6-42
Rear wheel ........................................................ 6-43
Troubleshooting ................................................. 6-45
Troubleshooting charts ...................................... 6-46
6
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00462
6-
EAU01790
Safety is an obligation of the owner.
Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of
motorcycle inspection, adjustment, and
lubrication are explained on the following pages.
Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual
that is certified (if applicable).
EW000060
6
WARNING
If you are not familiar with motorcycle maintenance work, have a
Yamaha dealer do it for you.
_
_
EAU00467
PERIODIC MAINTENANCE
PROPER PERIODIC MAINTENANCE
OF YOUR MOTORCYCLE IS IMPORTANT IN ORDER TO ENJOY LONG,
PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE
MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL.
THESE CONTROLS NOT ONLY
FUNCTION TO ENSURE CLEANER
AIR, BUT ARE ALSO VITAL TO
PROPER ENGINE OPERATION AND
MAXIMUM PERFORMANCE. IN THE
FOLLOWING PERIODIC MAINTENANCE CHARTS, THE SERVICES
RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY. THESE SERVICES REQUIRE
SPECIALIZED DATA, KNOWLEDGE,
AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED
TO PERFORM THESE PARTICULAR
SERVICES.
6-1
1. Owner’s tool kit
EAU01299
Owner’s tool kit
The owner’s tool kit is located inside
the storage compartment under the
seat. (See page 3-10 for seat removal
procedures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. However, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
U5LV10.book Page 2 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If you do not have the tools or experience required for a particular job, have
a Yamaha dealer perform it for you.
_
_
EW000063
WARNING
Modifications not approved by
Yamaha may cause loss of performance and render the vehicle unsafe
for use. Consult a Yamaha dealer before attempting any changes.
_
_
6
6-2
U5LV10.book Page 3 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00471
Periodic maintenance chart for the emission control system
CP-03E
INITIAL
No.
ITEM
1 * Valve clearance
6
ROUTINE
ODOMETER READINGS
20,000 mi
16,000 mi
12,000 mi
8,000 mi
4,000 mi
600 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
6 months 12 months 18 months 24 months 30 months
1 month
• Check and adjust valve clearance
when engine is cold.
Every 26,600 mi (42,000 km)
2
Spark plugs
• Check condition.
• Adjust gap and clean.
• Replace every 8,000 mi (13,000 km) or
12 months.
√
Replace.
√
Replace.
√
3 *
Crankcase
ventilation system
• Check ventilation hose for cracks or
damage.
• Replace if necessary.
√
√
√
√
√
4 * Fuel line
• Check fuel hoses and vacuum hose
for cracks or damage.
• Replace if necessary.
√
√
√
√
√
5 * Fuel filter
• Replace every 20,000 mi (31,000 km)
or 30 months.
6 * Exhaust system
• Check for leakage.
• Retighten if necessary.
• Replace gasket(s) if necessary.
7 *
Carburetor
synchronization
8 * Idle speed
• Adjust synchronization of carburetors.
Replace.
√
• Check and adjust engine idle speed.
• Adjust cable free play.
6-3
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
U5LV10.book Page 4 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
No.
9 *
10 *
ITEM
ROUTINE
Evaporative
emission control
system (For
California only)
• Check control system for damage.
• Replace if necessary.
Air induction
system
• Check the air cut valve and reed valve
for damage.
• Replace the entire air induction
system if necessary.
INITIAL
ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
20,000 mi
16,000 mi
12,000 mi
8,000 mi
4,000 mi
(7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
6 months 12 months 18 months 24 months 30 months
√
√
√
√
√
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
6
6-4
U5LV10.book Page 5 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00472
General maintenance and lubrication chart
INITIAL
No.
ITEM
ROUTINE
1
Engine oil
• Replace (warm engine before
draining). (See NOTE on page 6-7.)
√
2
Engine oil filter
cartridge
• Replace at initial 600 mi (1,000 km) or
1 month, and thereafter every
8,000 mi (13,000 km) or 12 months.
√
3 * Air filter element
4 * Cooling system
6
ODOMETER READINGS
20,000 mi
16,000 mi
12,000 mi
8,000 mi
4,000 mi
600 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
6 months 12 months 18 months 24 months 30 months
1 month
√
√
√
√
√
√
√
• Clean with compressed air.
• Replace if necessary.
√
√
√
√
√
• Check hose for cracks or damage.
• Replace if necessary.
√
√
√
√
√
• Replace coolant every 24 months. #3
Replace.
5 * Brake system
• Check operation, pad wear, and fluid
leakage. (See NOTE on page 6-7.)
• Correct if necessary.
√
√
√
√
√
√
6 * Clutch
• Check operation.
• Adjust or replace cable.
√
√
√
√
√
√
7 * Control cable
• Apply chain lube thoroughly. #1
√
√
√
√
√
√
Swingarm pivot
8 *
bearing
• Check bearing assembly for
looseness.
• Moderately repack every 16,000 mi
(25,000 km) or 24 months. #2
√
√
Repack.
• Check operation.
• Moderately repack every 16,000 mi
(25,000 km) or 24 months. #2
√
√
Repack.
9 *
Rear suspension
link pivots
6-5
U5LV10.book Page 6 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
No.
ITEM
ROUTINE
INITIAL
ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
20,000 mi
16,000 mi
12,000 mi
8,000 mi
4,000 mi
(7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
6 months 12 months 18 months 24 months 30 months
• Check operation and for oil leakage.
• Replace if necessary.
√
√
√
√
√
11 * Front fork
• Check operation and for oil leakage.
• Repair if necessary.
√
√
√
√
√
12 * Steering bearings
• Check bearing assembly for
looseness.
• Moderately repack every 16,000 mi
(25,000 km) or 24 months. #2
√
√
√
√
Repack.
√
10 *
Shock absorber
assembly
13
Brake and clutch
lever pivot shafts
• Lubricate. #2
√
√
√
√
√
14
Brake and shift
pedal pivot shafts
• Lubricate. #2
√
√
√
√
√
6
15 * Drive chain
• Check chain slack/alignment
condition.
• Adjust and lubricate chain thoroughly.
#1
16 * Wheel bearings
• Check bearings for smooth operation.
√
√
√
√
√
Sidestand and
17 * centerstand
pivots
• Check operation.
• Lubricate. #2
√
√
√
√
√
18 * Sidestand switch
• Check and clean or replace if
necessary.
√
√
√
√
√
Every 600 mi (1,000 km) or after washing the motorcycle
or riding in the rain.
√
6-6
U5LV10.book Page 7 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL
No.
ITEM
19 * Chassis fasteners
ROUTINE
ODOMETER READINGS
20,000 mi
16,000 mi
12,000 mi
8,000 mi
4,000 mi
600 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
6 months 12 months 18 months 24 months 30 months
1 month
• Check all chassis fitting and fasteners.
• Correct if necessary.
√
√
√
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
#1 : Yamaha chain lube
#2 : Lithium-soap-based grease (all-purpose grease)
#3 : Ethylene glycol anti-freeze coolant
EAU03907
NOTE:
From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.
_
_
6
EAU03234
NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
● Engine oil type
• Yamalube 4 (20W-40) or engine oil SAE 20W-40 (API SE) for temperatures of 5 °C (40 °F) or above.
• Yamalube 4 (10W-30) or engine oil SAE 10W-30 (API SE) for temperatures of 15 °C (60 °F) or below.
_
_
6-7
U5LV10.book Page 8 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Panel A
2. Panel B
1. Panel C
EAU01122
Removing and installing
panels
The panels shown above need to be
removed to perform some of the maintenance jobs described in this chapter.
Refer to this section each time a panel
needs to be removed and installed.
6
6-8
U5LV10.book Page 9 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Panel A
2. Screw
6
1. Panel C
2. Screw
1. Panel B
2. Screw (× 3)
EAU04003
EAU01315
Panels A and C
To remove one of the panels
Remove the screw, and then pull the
panel off as shown.
Panel B
To remove the panel
Remove the screws, and then take the
panel off.
To install the panel
Place the panel in the original position,
and then install the screw.
To install the panel
Place the panel in the original position,
and then install the screws.
6-9
U5LV10.book Page 10 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
_
_
1. Spark plug cap
1. Spark plug wrench
EAU03329
Checking the spark plugs
The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plugs can reveal the condition of the engine.
To remove a spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench included in the owner’s tool kit.
To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-tolight tan (the ideal color when the
motorcycle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.
6-10
3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace
it if necessary.
Specified spark plug:
CR9E (NGK) or
U27ESR-N (DENSO)
6
U5LV10.book Page 11 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
3. Install the spark plug with the
spark plug wrench, and then tighten it to the specified torque.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lb)
a. Spark plug gap
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
6
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
_
_
4. Install the spark plug cap.
2. Clean the surface of the spark
plug gasket and its mating surface, and then wipe off any grime
from the spark plug threads.
6-11
EAU01796
Canister (for California only)
This model is equipped with a canister
to prevent the discharging of fuel vapor
into the atmosphere.
● Check each hose connection.
● Check each hose and canister for
cracks or damage. Replace if
damaged.
● Make sure the vent hose is not
blocked. Clean it if necessary.
U5LV10.book Page 12 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
To change the engine oil
(with or without oil filter cartridge
replacement)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
EAU04050
Engine oil and oil filter
cartridge
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on the centerstand.
NOTE:
Make sure that the motorcycle is positioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading.
1.
2.
3.
4.
3. Wait a few minutes until the oil settles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.
_
_
Engine oil filler cap
Engine oil level check window
Maximum level mark
Minimum level mark
NOTE:
The engine oil should be between the
minimum and maximum level marks.
_
2. Start the engine, warm it up for
several minutes, and then turn it
off.
_
4. If the engine oil is below the minimum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
6-12
6
U5LV10.book Page 13 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Engine oil drain bolt
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
6
NOTE:
● Skip steps 4–6 if the oil filter cartridge is not being replaced.
● When draining the engine oil, use
a funnel or similar device to keep
the oil away from the exhaust pipe.
_
1. Oil filter wrench
2. Oil filter cartridge
1. O-ring
4. Remove the oil filter cartridge with
an oil filter wrench.
5. Apply a thin coat of engine oil to
the O-ring of the new oil filter cartridge.
NOTE:
An oil filter wrench is available at a
Yamaha dealer.
NOTE:
Make sure that the O-ring is properly
seated.
_
_
_
_
_
6-13
U5LV10.book Page 14 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
1. Torque wrench
6. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lb)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
2.8 L (2.46 Imp qt, 2.96 US qt)
With oil filter cartridge
replacement:
3 L (2.64 Imp qt, 3.17 US qt)
Total amount (dry engine):
3.7 L (3.26 Imp qt, 3.91 US qt)
EC000072
_
CAUTION:
● In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
● Make sure that no foreign material enters the crankcase.
_
9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
NOTE:
After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient.
7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
_
_
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lb)
6-14
6
U5LV10.book Page 15 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000067
CAUTION:
If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha dealer check the vehicle.
_
_
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU03957
Coolant
The coolant level should be checked
before each ride. In addition, the coolant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the coolant level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:
● The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
● Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
2. Check the coolant level in the
coolant reservoir.
_
6
_
NOTE:
The coolant should be between the
minimum and maximum level marks.
_
_
3. If the coolant is at or below the
minimum level mark, open the reservoir cap, add coolant to the maximum level mark, and then close
the reservoir cap.
Coolant reservoir capacity:
0.3 L (0.26 Imp, 0.32 US qt)
6-15
U5LV10.book Page 16 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000080
NOTE:
● The radiator fan is automatically
switched on or off according to the
coolant temperature in the radiator.
● If the engine overheats, see
page 6-47 for further instructions.
_
_
CAUTION:
● If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
● If water has been used instead
of coolant, replace it with coolant as soon as possible, otherwise the engine may not be
sufficiently cooled and the cooling system will not be protected
against frost and corrosion.
● If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
_
6
_
EW000067
WARNING
Never attempt to remove the radiator cap when the engine is hot.
_
_
6-16
U5LV10.book Page 17 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03958
To change the coolant
1. Place the motorcycle on the centerstand and let the engine cool if
necessary.
2. Remove panel B. (See page 6-9
for panel removal and installation
procedures.)
1. Coolant drain bolt
1. Radiator cap
6. After the coolant is completely
drained, thoroughly flush the cooling system with clean tap water.
7. Install the coolant drain bolt, and
then tighten it to the specified
torque.
3. Place a container under the engine to collect the used coolant.
4. Remove the radiator cap.
EW000067
6
WARNING
Never attempt to remove the radiator cap when the engine is hot.
_
_
5. Remove the coolant drain bolt to
drain the cooling system.
NOTE:
Check the washer for damage and replace it if necessary.
_
_
Tightening torque:
Coolant drain bolt:
7 Nm (0.7 m·kgf, 5.1 ft·lb)
6-17
U5LV10.book Page 18 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
8. Pour the recommended coolant
into the radiator until it is full.
EC000080
_
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Antifreeze/water mixture ratio:
1:1
Coolant quantity:
Total amount:
2.4 L (2.11 Imp qt, 2.54 US qt)
Coolant reservoir capacity:
0.3 L (0.26 Imp qt, 0.32 US qt)
CAUTION:
● If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
● If water has been used instead
of coolant, replace it with coolant as soon as possible, otherwise the engine may not be
sufficiently cooled and the cooling system will not be protected
against frost and corrosion.
● If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.
_
6-18
9. Install the radiator cap, start the
engine, let it idle for several minutes, and then turn it off.
10. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radiator, and then install the radiator
cap.
11. Check the coolant level in the reservoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
12. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
13. Install the panel.
6
U5LV10.book Page 19 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU04051*
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more frequently if you are riding in unusually
wet or dusty areas.
1. Remove the seat. (See page 3-10
for seat removal and installation
procedures.)
1. Bolt (× 3)
2. Remove the fuel tank bolts.
3. Lift the fuel tank to position it away
from the air filter case. (Do not disconnect the fuel hoses!)
6
EW000071
_
WARNING
● Make sure that the fuel tank is
well supported.
● Do not tilt or pull the fuel tank
too much, otherwise the fuel
hoses may come loose, which
could cause fuel leakage.
_
4. Remove panels A and C. (See
page 6-9 for panel removal and installation procedures.)
6-19
1. Rubber cover
2. Rubber cover holder
5. Pull the rubber cover off its holders.
U5LV10.book Page 20 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Air filter case cover
2. Screw (× 4)
1. Air filter element
1. Air filter element
7. Pull the air filter element out.
6. Remove the air filter case cover by
removing the screws.
6-20
8. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.
9. Insert the air filter element into the
air filter case.
6
U5LV10.book Page 21 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
ECA00089*
EAU00628
Adjusting the carburetors
CAUTION:
The engine should never be operated without the air filter element installed, otherwise the pistons and/or
cylinders may become excessively
worn.
_
The carburetors are important parts of
the engine and emission control system, which require very sophisticated
adjustment. Therefore, all carburetor
adjustments should be left to a
Yamaha dealer, who has the necessary professional knowledge and
experience.
_
6
10. Install the air filter case cover by
installing the screws.
11. Place the rubber cover in the original position.
12. Install the panels.
13. Install the fuel tank by installing the
bolts.
1. Fuel tank breather hose
2. Original position (white mark)
EWA00052
_
WARNING
Before installing the fuel tank,
make sure that the fuel hoses
are not damaged. If any fuel
hose is damaged, do not start
the engine but have a Yamaha
dealer replace the hose, otherwise fuel may leak.
● Make sure that the fuel hoses
are properly connected and
routed, and not pinched.
● Be sure to place the fuel tank
breather hose in the original position.
●
_
14. Install the seat.
6-21
U5LV10.book Page 22 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00637
Adjusting the valve clearance
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
a. Throttle cable free play
EAU00635
Adjusting the throttle cable
free play
The throttle cable free play should
measure 3–5 mm (0.1–0.2 in) at the
throttle grip. Periodically check the
throttle cable free play and, if necessary, have a Yamaha dealer adjust it.
6
6-22
U5LV10.book Page 23 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03581
CE-22E
Tires
To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
_
6
WARNING
● The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
● The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, cargo, and accessories approved
for this model.
EW000083
Tire air pressure
(measured on cold tires)
WARNING
Proper loading of your motorcycle
is important for several characteristics of your motorcycle, such as
handling, braking, performance and
safety. Do not carry loosely packed
items that can shift. Securely pack
your heaviest items close to the
center of the motorcycle, and distribute the weight evenly from side
to side. Properly adjust the suspension for your load, and check the
condition and pressure of your tires.
NEVER OVERLOAD YOUR MOTORCYCLE. Make sure that the total
weight of the cargo, rider, passenger, and accessories (cowling, saddlebags, etc. if approved for this
model) does not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle
could cause tire damage, an accident, or even injury.
_
Load*
Front
Rear
Up to 90 kg (198 lb)
250 kPa
270 kPa
(2.50 kgf/cm2, (2.70 kgf/cm2,
36 psi)
39 psi)
90 kg (198 lb)–
maximum
250 kPa
290 kPa
(2.50 kgf/cm2, (2.90 kgf/cm2,
36 psi)
42 psi)
High-speed riding
250 kPa
290 kPa
(2.50 kgf/cm2, (2.90 kgf/cm2,
36 psi)
42 psi)
CE-16E
Maximum load*
FZS1000: 189 kg (417 lb)
FZS1000C: 188 kg (415 lb)
* Total weight of rider, passenger, cargo and
accessories
_
_
6-23
U5LV10.book Page 24 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000094
_
1. Tire sidewall
2. Tire wear indicator
a. Tire tread depth
Tire inspection
Always check the tires before operating
the motorcycle. If a tire tread shows
crosswise lines (minimum tread depth),
if the tire has a nail or glass fragments
in it, or if the side wall is cracked, contact a Yamaha dealer immediately and
have the tire replaced.
WARNING
● It is dangerous to ride with a
worn-out tire. When a tire tread
begins to show crosswise lines,
have a Yamaha dealer replace
the tire immediately.
● The replacement of all wheeland brake-related parts, including the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowledge and experience.
_
CE-09E
Minimum tire tread depth
(front and rear)
1.0 mm (0.04 in)
6-24
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
6
U5LV10.book Page 25 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000080
_
●
●
●
6
●
WARNING
The front and rear tires should
be of the same make and design, otherwise the handling
characteristics of the motorcycle cannot be guaranteed.
After extensive tests, only the
tires listed below have been approved for this model by
Yamaha Motor Co., Ltd.
Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.
Use only the tire valves and
valve cores listed below to
avoid tire deflation during a
high-speed ride.
CE-10E
FRONT
EAU00684
Manufacturer
Size
Model
Bridgestone
120/70 ZR17 (58W)
BT020F
WARNING
This motorcycle is fitted with superhigh-speed tires. Note the following
points in order to make the most efficient use of these tires.
● Use only the specified replacement tires. Other tires may run
the danger of bursting at super
high speeds.
● Brand-new tires can have a relatively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is advisable before doing any highspeed riding to ride conservatively for approximately 100 km
after installing a new tire.
● The tires must be warmed up
before a high-speed run.
● Always adjust the tire air pressure according to the operating
conditions.
_
REAR
Manufacturer
Size
Model
Bridgestone
180/55 ZR17 (73W)
BT020R
CE-14E
FRONT & REAR
Tire air valve
TR412
Valve core
#9000A (original)
_
_
6-25
U5LV10.book Page 26 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03773
Cast wheels
To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified wheels.
● The wheel rims should be checked
for cracks, bends or warpage before each ride. If any damage is
found, have a Yamaha dealer replace the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.
● The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse handling characteristics, and a shortened tire life.
● Ride at moderate speeds after
changing a tire since the tire surface must first be “broken in” for it to
develop its optimal characteristics.
EAU00691
Accessories and replacement
parts
by the use of items which have not
been approved by Yamaha.
_
EW000098
WARNING
This motorcycle is not designed to
pull a trailer or to be attached to a
sidecar. The accessories or replacement parts you choose for your
motorcycle should be designed specifically for this model, and they
must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts
and Accessories are designed and
tested to be compatible with your
motorcycle. Please consider Genuine Yamaha Parts and Accessories
before making a purchase. Use of
non-Yamaha-approved accessories
or replacement parts may cause
loss of handling stability and riding
safety. Since Yamaha cannot control the quality of accessories or
parts manufactured by other companies, Yamaha cannot be held liable for any consequences caused
_
6-26
6
U5LV10.book Page 27 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If the specified free play cannot be obtained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internal
clutch mechanism.
_
_
1. Clutch lever free play adjusting bolt
c. Clutch lever free play
a. Distance between brake pedal and footrest
EAU00712
Adjusting the brake pedal
position
EAU04005
Adjusting the clutch lever free
play
6
The top of the brake pedal should be positioned approximately 43 mm (1.7 in)
below the top of the footrest as shown.
Periodically check the brake pedal position and, if necessary, have a Yamaha
dealer adjust it.
The clutch lever free play should measure 10–15 mm (0.4–0.6 in) as shown.
Periodically check the clutch lever free
play and, if necessary, adjust it as follows.
To increase the clutch lever free play,
turn the adjusting bolt in direction a.
To decrease the clutch lever free play,
turn the adjusting bolt in direction b.
6-27
U5LV10.book Page 28 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000109
WARNING
A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system before operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident.
_
_
1. Rear brake light switch
2. Rear brake light switch adjusting nut
EAU00713
Adjusting the rear brake light
switch
The rear brake light switch, which is activated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction a. To
make the brake light come on later,
turn the adjusting nut in direction b.
6-28
6
U5LV10.book Page 29 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Rear
Front
1. Brake pad wear indicator groove
1. Brake pad wear indicator groove
EAU01314
Checking the front and rear
brake pads
6
Front brake
The front and rear brake pads must be
checked for wear at the intervals specified in the periodic maintenance and
lubrication chart. Each brake pad is
provided with a wear indicator groove,
which allows you to check the brake
pad wear without having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator groove has almost disappeared, have a Yamaha dealer replace
the brake pads as a set.
6-29
1. Minimum level mark
EAU03776
Checking the brake fluid level
Insufficient brake fluid may allow air to
enter the brake system, possibly causing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake system for leakage.
U5LV10.book Page 30 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Rear brake
1. Minimum level mark
Observe these precautions:
● When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
● Use only the recommended quality brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking performance.
●
Be careful that water does not enter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
● Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid
immediately.
● As the brake pads wear, it is normal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.
Recommended brake fluid: DOT 4
●
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
6-30
EAU03976
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic maintenance and lubrication chart. In addition,
have the oil seals of the master cylinders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
● Oil seals: Replace every two
years.
● Brake hoses: Replace every four
years.
6
U5LV10.book Page 31 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Drive chain slack:
40–50 mm (1.6–2.0 in)
5. If the drive chain slack is incorrect,
adjust it as follows.
a. Drive chain slack
1.
2.
3.
4.
EAU00745
Drive chain slack
6
The drive chain slack should be
checked before each ride and adjusted
if necessary.
Axle nut
Drive chain slack adjusting bolt
Locknut
Alignment marks
EAU03608
To adjust the drive chain slack
1. Loosen the axle nut and the locknut on each side of the swingarm.
2. To tighten the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction a. To loosen the drive chain, turn the adjusting bolt on each side of the
swingarm in direction b, and then
push the rear wheel forward.
To check the drive chain slack
1. Place the motorcycle on the centerstand.
2. Shift the transmission into the neutral position.
3. Spin the rear wheel several times
to locate the tightest portion of the
drive chain.
4. Measure the drive chain slack as
shown.
6-31
U5LV10.book Page 32 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same position for proper wheel alignment.
_
_
EC000096
CAUTION:
Improper drive chain slack will overload the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.
_
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrication chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
EC000097
CAUTION:
The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.
_
1. Clean the drive chain with kerosene and a small soft brush.
ECA00053
CAUTION:
To prevent damaging the O-rings,
do not clean the drive chain with
steam
cleaners,
high-pressure
washers or inappropriate solvents.
_
Tightening torque:
Axle nut:
150 Nm (15.0 m·kgf, 108 ft·lb)
ECA00052
CAUTION:
Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
_
_
_
_
3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
EAU03006
Lubricating the drive chain
_
6-32
6
U5LV10.book Page 33 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03297
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EAU03370
Recommended lubricant:
Yamaha Chain and Cable Lube
or engine oil SAE 10W-30
(API SE)
6
EW000111
WARNING
Damage to the outer housing of cables may result in internal rusting
and cause interference with cable
movement. Replace damaged cables as soon as possible to prevent
unsafe conditions.
EAU03164
Checking and lubricating the
brake and shift pedals
Checking and lubricating the
brake and clutch levers
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lubricated if necessary.
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lubricated if necessary.
_
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
_
6-33
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5LV10.book Page 34 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03166
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Lubricating the rear
suspension
The pivoting points of the rear suspension must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
EAU03371
Checking and lubricating the
centerstand and sidestand
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-tometal contact surfaces should be lubricated if necessary.
6
EW000114
WARNING
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or repair it.
_
_
6-34
U5LV10.book Page 35 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02939
EAU00794
Checking the front fork
Checking the steering
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
To check the condition
EW000115
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
_
_
6
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handlebars several times to check if the
front fork compresses and rebounds smoothly.
EC000098
CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
_
_
6-35
EW000115
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
_
_
U5LV10.book Page 36 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01144
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrication chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
2. Hold the lower ends of the front
fork legs and try to move them forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the
steering.
6
6-36
U5LV10.book Page 37 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quantities of water or milk and immediately call a physician.
• EYES: Flush with water for
15 minutes and seek prompt
medical attention.
● Batteries produce explosive hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed
space.
● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
EAU00800
Battery
This motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
EC000101
CAUTION:
Never attempt to remove the battery
cell seals, as this would permanently damage the battery.
_
_
EW000116
6
_
●
WARNING
Electrolyte is poisonous and
dangerous since it contains sulfuric acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and always shield your eyes when
working near batteries. In case
of contact, administer the following FIRST AID.
_
6-37
To charge the battery
Have a Yamaha dealer charge the battery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the motorcycle is equipped with optional electrical accessories.
To store the battery
1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check it at
least once a month and fully
charge it if necessary.
3. Fully charge the battery before installation.
4. After installation, make sure that
the battery leads are properly connected to the battery terminals.
U5LV10.book Page 38 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
EC000102
_
_
CAUTION:
keep the battery
● Always
charged. Storing a discharged
battery can cause permanent
battery damage.
● To charge a sealed-type (MF)
battery, a special (constantvoltage) battery charger is required. Using a conventional
battery charger will damage the
battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha
dealer charge your battery.
1.
2.
3.
4.
5.
6.
7.
Specified fuses:
Main fuse:
Headlight fuse:
Signaling system fuse:
Radiator fan fuse:
Ignition fuse:
Backup fuse
(odometer and clock):
Main fuse
Headlight fuse
Radiator fan fuse
Ignition fuse
Signaling system fuse
Backup fuse (odometer and clock)
Spare fuse (× 3)
10 A
EC000103
EAU04102
Replacing the fuses
The main fuse box and the fuse box,
which contains the fuses for the individual circuits, are located under the seat.
(See page 3-10 for seat removal and
installation procedures.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
6-38
30 A
20 A
20 A
10 A
20 A
CAUTION:
Do not use a fuse of a higher amperage rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
_
_
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
6
U5LV10.book Page 39 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Headlight bulb cover
2. Headlight coupler
1. Headlight bulb holder
EAU03960
Replacing a headlight bulb
6
This motorcycle is equipped with two
quartz bulb headlights. If a headlight
bulb burns out, replace it as follows.
1. Remove panel B. (See page 6-9
for panel removal and installation
procedures.)
2. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.
3. Unhook the headlight bulb holder,
and then remove the defective
bulb.
1. Do not touch this area.
EW000119
WARNING
Headlight bulbs get very hot. Therefore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
_
_
4. Place a new bulb into position, and
then secure it with the bulb holder.
6-39
U5LV10.book Page 40 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000104
CAUTION:
Take care not to damage the following parts:
● Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life
will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb
using a cloth moistened with alcohol or thinner.
● Headlight lens
• Do not affix any type of tinted
film or stickers to the headlight lens.
• Do not use a headlight bulb of
a wattage higher than specified.
_
5. Install the bulb cover, and then
connect the coupler.
6. Install the panel.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
6
_
6-40
U5LV10.book Page 41 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Tail/brake light bulb cover
1. Socket
EAU03961
Replacing a tail/brake light
bulb
6
1. Remove the seat. (See page 3-10
for seat removal and installation
procedures.)
2. Remove the tail/brake light bulb
cover.
1. Screw
3. Remove the socket (together with
the bulb) by turning it counterclockwise.
4. Remove the defective bulb by
pushing it in and turning it counterclockwise.
5. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
6. Install the socket (together with
the bulb) by turning it clockwise.
7. Install the bulb cover.
8. Install the seat.
6-41
EAU03497
Replacing a turn signal light
bulb
1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
4. Install the lens by installing the
screw.
U5LV10.book Page 42 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
ECA00065
CAUTION:
Do not overtighten the screw, otherwise the lens may break.
_
_
1. Wheel axle
2. Front wheel axle pinch bolt
EAU03962
1. Brake hose holder
2. Bolt (× 2)
3. Brake caliper
Front wheel
3. Remove the brake hose holder on
each side by removing the bolts.
4. Remove the brake caliper on each
side by removing the bolts.
To remove the front wheel
EW000122
_
WARNING
It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motorcycle so that there is no danger
of it falling over.
●
_
ECA00046
CAUTION:
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
_
_
1. Place the motorcycle on the centerstand.
2. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.
6-42
5. Pull the wheel axle out, and then
remove the wheel.
6
U5LV10.book Page 43 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03963
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
4. Install the brake calipers by installing the bolts.
NOTE:
Make sure that there is enough space
between the brake pads before installing the brake calipers onto the brake
discs.
_
6
Tightening torques:
Wheel axle:
72 Nm (7.2 m·kgf, 52 ft·lb)
Front wheel axle pinch bolt:
19 Nm (1.9 m·kgf, 14 ft·lb)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lb)
7. Push down hard on the handlebar
several times to check for proper
fork operation.
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
EAU03964
Rear wheel
To remove the rear wheel
_
5. Install the brake hose holders by
installing the bolts.
6. Tighten the wheel axle, the wheel
axle pinch bolt and the brake caliper bolts to the specified torques.
EW000122
_
WARNING
● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motorcycle so that there is no danger
of it falling over.
_
1. Loosen the axle nut and the brake
caliper bolts.
2. Place the motorcycle on the centerstand.
6-43
U5LV10.book Page 44 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
5. Loosen the locknut on each side of
the swingarm.
6. Turn the drive chain slack adjusting bolts fully in direction a.
7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the rear wheel.
_
1.
2.
3.
4.
Bolt (× 2)
Brake torque rod
Brake torque rod nut
Brake caliper bracket
_
3. Disconnect the brake torque rod
from the brake caliper by removing
the nut and the bolt.
4. Remove the axle nut, then the
brake caliper by removing the
bolts.
8. While supporting the wheel, pull
the wheel axle out.
9. Remove the wheel.
ECA00082
CAUTION:
Do not apply the brake after the
brake caliper has been removed,
otherwise the brake pads will be
forced shut.
_
_
6-44
6
U5LV10.book Page 45 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
5. Install the brake caliper by installing the bolts.
NOTE:
Make sure that there is enough space
between the brake pads before installing the brake caliper onto the brake
disc.
_
_
EAU03895
6
To install the rear wheel
1. Place the wheel and the brake caliper bracket in the original position.
2. Insert the wheel axle through the
brake caliper bracket and wheel
from the right-hand side, and then
install the axle nut.
3. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-31 for
drive chain slack adjustment procedures.)
4. Connect the brake torque rod to
the brake caliper bracket by installing the bolt and the nut.
6. Take the motorcycle off the centerstand so that the rear wheel is
on the ground.
7. Tighten the axle nut, brake caliper
bolts and brake torque rod nut to
the specified torques.
Tightening torques:
Axle nut:
150 Nm (15.0 m·kgf, 108 ft·lb)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lb)
Brake torque rod nut:
23 Nm (2.3 m·kgf, 17 ft·lb)
6-45
EAU03087
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur during operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems yourself. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replacement parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
U5LV10.book Page 46 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02990
Troubleshooting charts
Starting problems or poor engine performance
EW000125
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
_
_
1. Fuel
There is enough fuel.
Check the compression.
There is no fuel.
Supply fuel.
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer
check the vehicle.
Check the fuel level in
the fuel tank.
The engine does not start.
Check the compression.
2. Compression
Operate the electric starter.
3. Ignition
6
Wet
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Open the throttle halfway and operate
the electric starter.
Dry
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.
Remove the spark plugs
and check the electrodes.
4. Battery
The engine turns over
quickly.
The battery is good.
The engine turns over
slowly.
Check the battery lead connections,
and charge the battery if necessary.
Operate the electric starter.
6-46
The engine does not start.
Have a Yamaha dealer
check the vehicle.
U5LV10.book Page 47 Wednesday, October 23, 2002 2:45 PM
PERIODIC MAINTENANCE AND MINOR REPAIR
Engine overheating
EW000070
_
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
● After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
●
_
The coolant level is low.
Check the cooling system
for leakage.
6
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
There is
leakage.
There is
no leakage.
Have a Yamaha dealer check
and repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
_
_
6-47
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
MOTORCYCLE CARE AND STORAGE
Care .................................................................................................. 7-1
Storage .............................................................................................. 7-4
7
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
MOTORCYCLE CARE AND STORAGE
EAU03426
7-
Care
While the open design of a motorcycle
reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts
from the overall appearance of a
motorcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
7
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such products onto seals, gaskets, sprockets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.
7-1
Cleaning
ECA00010
_
CAUTION:
● Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a
corrosion protection spray.
● Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
U5LV10.book Page 2 Wednesday, October 23, 2002 2:45 PM
MOTORCYCLE CARE AND STORAGE
●
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
● Do not use high-pressure washers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes),
electric components (couplers,
connectors, instruments, switches and lights), breather hoses
and vents.
●
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the windshield. Test the product on a
small hidden part of the windshield to make sure that it does
not leave any marks. If the windshield is scratched, use a quality plastic polishing compound
after washing.
_
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
7-2
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.
NOTE:
Salt sprayed on roads in the winter may
remain well into spring.
_
_
1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
7
U5LV10.book Page 3 Wednesday, October 23, 2002 2:45 PM
MOTORCYCLE CARE AND STORAGE
ECA00012
CAUTION:
Do not use warm water since it increases the corrosive action of the
salt.
_
_
2. Apply a corrosion protection spray
on all metal, including chromeand nickel-plated, surfaces to prevent corrosion.
7
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainlesssteel parts, including the exhaust
system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)
4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, surfaces.
5. Use spray oil as a universal cleaner to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
7-3
EWA00001
_
_
WARNING
● Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or acetone, and wash the tires with
warm water and a mild detergent.
● Before operating the motorcycle test its braking performance and cornering behavior.
U5LV10.book Page 4 Wednesday, October 23, 2002 2:45 PM
MOTORCYCLE CARE AND STORAGE
ECA00013
_
CAUTION:
● Apply spray oil and wax sparingly and make sure to wipe off
any excess.
● Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
● Avoid using abrasive polishing
compounds as they will wear
away the paint.
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00014
_
_
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
_
_
CAUTION:
● Storing the motorcycle in a
poorly ventilated room or covering it with a tarp, while it is still
wet, will allow water and humidity to seep in and cause rust.
● To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
_
7-4
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” position: Turn the fuel cock lever to
“OFF”.
3. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to protect the cylinders, piston rings, etc.
from corrosion.
a. Remove the spark plug caps and
spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.
7
U5LV10.book Page 5 Wednesday, October 23, 2002 2:45 PM
MOTORCYCLE CARE AND STORAGE
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alternatively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an excessively cold or warm place [less
than 0 °C (30 °F) or more than
30 °C (90 °F)]. For more information on storing the battery, see
page 6-37.
c. Install the spark plug caps onto the
spark plugs, and then place the
spark plugs on the cylinder head
so that the electrodes are grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times
with the starter. (This will coat the
cylinder walls with oil.)
e. Remove the spark plug caps from
the spark plugs, and then install
the spark plugs and the spark plug
caps.
EWA00003
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
_
7
_
6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
NOTE:
Make any necessary repairs before
storing the motorcycle.
_
_
7-5
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
SPECIFICATIONS
Specifications .................................................................................... 8-1
8
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
SPECIFICATIONS
EAU01038
8-
Specifications
CS-01E
Model
FZS1000
Engine oil
Type
Dimensions
Overall length
Overall width
Overall height
Wheelbase
1,450 mm (57.1 in)
SAE 15W-40
SAE 20W-40
140 mm (5.5 in)
SAE 20W-50
2,900 mm (114.2 in)
Recommended engine oil
classification
Basic weight (with oil and full
fuel tank)
FZS1000
231 kg (509 lb)
FZS1000C
232 kg (512 lb)
Engine type
Liquid-cooled 4-stroke, DOHC
Cylinder arrangement
Forward-inclined parallel
4-cylinder
Displacement
998 cm3
Bore × Stroke
74 × 58 mm (2.9 × 2.3 in)
Compression ratio
11.4:1
Starting system
Electric starter
Lubrication system
Wet sump
API Service SE, SF, SG or
higher
CAUTION:
Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
“ENERGY CONSERVING II”) contain anti-friction additives
which will cause clutch and/or starter clutch slippage, resulting in reduced component life and poor engine performance.
Engine
8
10 20 30 40 50 ˚C
SAE 10W-40
1,190 mm (46.9 in)
820 mm (32.3 in)
Minimum turning radius
0
SAE 10W-30
765 mm (30.1 in)
Seat height
Ground clearance
-20 -10
2,125 mm (83.7 in)
Quantity
8-1
Without oil filter cartridge
replacement
2.8 L (2.46 Imp qt, 2.96 US qt)
With oil filter cartridge
replacement
3 L (2.64 Imp qt, 3.17 US qt)
Total amount (dry engine)
3.7 L (3.26 Imp qt, 3.91 US qt)
U5LV10.book Page 2 Wednesday, October 23, 2002 2:45 PM
SPECIFICATIONS
Cooling system capacity
(total amount)
2.4 L (2.11 Imp qt, 2.54 US qt)
Number of drive chain
sprocket teeth (front/rear)
16/44
Air filter
Dry type element
Transmission type
Constant-mesh 6-speed
Operation
Left foot
Fuel
Type
Unleaded fuel
Gear ratio
Fuel tank capacity
21 L (4.6 Imp gal, 5.5 US gal)
1st
2.500
Fuel reserve amount
4 L (0.9 Imp gal, 1.1 US gal)
2nd
1.842
Carburetor
3rd
1.500
Manufacturer
MIKUNI
4th
1.333
Model × quantity
BSR37 × 4
5th
1.200
6th
1.115
Spark plug
Manufacturer/type
NGK / CR9E or
DENSO / U27ESR-N
Gap
0.7–0.8 mm (0.028–0.031 in)
Clutch type
Chassis
Frame type
Wet, multiple-disc
Transmission
Double cradle
Caster angle
26°
Trail
104 mm (4.1 in)
Tires
Primary reduction system
Spur gear
Primary reduction ratio
1.581
Secondary reduction system
Chain drive
Secondary reduction ratio
2.750
Front
8-2
Type
Tubeless tire
Size
120/70 ZR17 (58W)
Manufacturer/
model
Bridgestone / BT020F
8
U5LV10.book Page 3 Wednesday, October 23, 2002 2:45 PM
SPECIFICATIONS
Rear
Rear
Type
Tubeless tire
Type
Cast wheel
Size
180/55 ZR17 (73W)
Size
17 × MT 5.50
Manufacturer/
model
Bridgestone / BT020R
Type
Dual disc brake
Operation
Right hand
Fluid
DOT 4
Type
Single disc brake
Operation
Right foot
Fluid
DOT 4
Brakes
Front
Maximum load*
FZS1000
189 kg (417 lb)
FZS1000C
188 kg (415 lb)
Tire air pressure (measured
on cold tires)
Rear
Up to 90 kg (198 lb)*
Front
250 kPa (2.50 kgf/cm2, 36 psi)
Rear
270 kPa (2.70 kgf/cm2, 39 psi)
Suspension
90 kg (198 lb)–maximum*
Front
Rear
250 kPa (2.50 kgf/cm2, 36 psi)
Front
Telescopic fork
290 kPa (2.90 kgf/cm2, 42 psi)
Rear
Swingarm (link suspension)
Spring/shock absorber
High-speed riding
8
Front
250 kPa (2.50 kgf/cm2, 36 psi)
Rear
290 kPa (2.90 kgf/cm2, 42 psi)
* Total weight of rider, passenger, cargo and accessories
Front
Cast wheel
Size
17 × MT 3.50
Coil spring / oil damper
Rear
Coil spring / gas-oil damper
Wheel travel
Wheels
Type
Front
8-3
Front
140 mm (5.5 in)
Rear
135 mm (5.3 in)
U5LV10.book Page 4 Wednesday, October 23, 2002 2:45 PM
SPECIFICATIONS
Electrical system
Ignition system
Fuses
T.C.I. (digital)
Charging system
Main fuse
30 A
Headlight fuse
20 A
Model
A.C. magneto
Radiator fan fuse
10 A
Standard output
14 V, 365 W @ 5,000 r/min
Ignition fuse
20 A
Signaling system fuse
20 A
Model
GT14B-4
Voltage, capacity
12 V, 12 Ah
Backup fuse (odometer and
clock)
10 A
Battery
Headlight type
Quartz bulb (halogen)
Bulb voltage, wattage × quantity
Headlight
12 V, 60/55 W × 2
Tail/brake light
12 V, 5/21 W × 2
Front turn signal/position light
12 V, 27/8 W × 2
Rear turn signal light
12 V, 27 W × 2
Meter lighting
12 V, 2 W × 3
Neutral indicator light
14 V, 1.4 W × 1
High beam indicator light
14 V, 1.4 W × 1
Oil level warning light
14 V, 1.4 W × 1
Turn signal indicator light
14 V, 1.4 W × 2
Fuel level warning light
12 V, 2 W × 1
Coolant temperature warning
light
LED
8
8-4
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
CONSUMER INFORMATION
Identification numbers ....................................................................... 9-1
Key identification number .................................................................. 9-1
Vehicle identification number ............................................................. 9-1
Model label ........................................................................................ 9-2
Reporting safety defects ................................................................... 9-3
Motorcycle noise regulation .............................................................. 9-4
Maintenance record .......................................................................... 9-5
YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO
MOTORCYCLE LIMITED WARRANTY ........................................... 9-7
YAMAHA EXTENDED SERVICE (Y.E.S.) ......................................... 9-9
9
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
CONSUMER INFORMATION
EAU01039
9-
EAU02944
Identification numbers
Record the key identification number,
vehicle identification number and model label information in the spaces provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is stolen.
1. Key identification number
1. KEY IDENTIFICATION NUMBER:
CA-02E
2. VEHICLE IDENTIFICATION
NUMBER:
EAU01043
EAU01041
Key identification number
Vehicle identification number
The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space provided.
CA-02E
9
1. Vehicle identification number
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcycle with the licensing authority in
your area.
_
3. MODEL LABEL INFORMATION:
CA-01E
_
9-1
U5LV10.book Page 2 Wednesday, October 23, 2002 2:45 PM
CONSUMER INFORMATION
1. Model label
EAU01050
Model label
The model label is affixed to the frame
under the seat. (See page 3-10 for seat
removal and installation procedures.)
Record the information on this label in
the space provided. This information
will be needed when ordering spare
parts from a Yamaha dealer.
9
9-2
U5LV10.book Page 3 Wednesday, October 23, 2002 2:45 PM
CONSUMER INFORMATION
EAU01051
Reporting safety defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,
U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Yamaha Motor Corporation, U.S.A.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline.
9
9-3
U5LV10.book Page 4 Wednesday, October 23, 2002 2:45 PM
CONSUMER INFORMATION
EAU01053
Motorcycle noise regulation
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other
than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of
the vehicle after such device or element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.
These acts include tampering with the following systems; i.e., modification, removal, etc.
CL-01E
Exhaust system
Muffler
Exhaust pipe
Silencer
Intake system
Air cleaner case
Air cleaner element
Intake duct
9
9-4
U5LV10.book Page 5 Wednesday, October 23, 2002 2:45 PM
CONSUMER INFORMATION
EAU01874
Maintenance record
Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that
maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder
that maintenance work is required. It is not acceptable proof of maintenance work.
CL-04E
Maintenance
interval
Date of
service
Servicing dealer
name and address
Mileage
600 mi
(1,000 km) or
1 month
4,000 mi
( 7,000 km) or
6 months
8,000 mi
(13,000 km) or
12 months
12,000 mi
(19,000 km) or
18 months
16,000 mi
(25,000 km) or
24 months
9
20,000 mi
(31,000 km) or
30 months
24,000 mi
(37,000 km) or
36 months
9-5
Remarks
U5LV10.book Page 6 Wednesday, October 23, 2002 2:45 PM
CONSUMER INFORMATION
Maintenance
interval
Date of
service
Servicing dealer
name and address
Mileage
Remarks
28,000 mi
(43,000 km) or
42 months
32,000 mi
(49,000 km) or
48 months
36,000 mi
(55,000 km) or
54 months
40,000 mi
(61,000 km) or
60 months
9
9-6
U5LV10.book Page 7 Wednesday, October 23, 2002 2:45 PM
CONSUMER INFORMATION
EAU02918
YAMAHA MOTOR CORPORATION, U.S.A.
STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY
9
9-7
U5LV10.book Page 8 Wednesday, October 23, 2002 2:45 PM
CONSUMER INFORMATION
9
9-8
U5LV10.book Page 9 Wednesday, October 23, 2002 2:45 PM
CONSUMER INFORMATION
EAU01063
YAMAHA EXTENDED SERVICE (Y.E.S.)
9
9-9
U5LV10.book Page 10 Wednesday, October 23, 2002 2:45 PM
CONSUMER INFORMATION
9
9-10
U5LV10.book Page 1 Wednesday, October 23, 2002 2:45 PM
INDEX
A
Accessories and replacement parts .......6-26
Air filter element, cleaning ......................6-19
B
Battery ...................................................6-37
Brake and clutch levers, checking and
lubricating ............................................6-33
Brake and shift pedals, checking and
lubricating ............................................6-33
Brake fluid, changing .............................6-30
Brake fluid level, checking......................6-29
Brake lever...............................................3-7
Brake light switch (rear), adjusting .........6-28
Brake pads, checking.............................6-29
Brake pedal..............................................3-7
Brake pedal position, adjusting ..............6-27
C
Drive chain, lubricating .......................... 6-32
Drive chain slack ................................... 6-31
Adjusting .......................................... 6-31
Checking.......................................... 6-31
Labels, location ........................................1-7
M
Engine break-in ....................................... 5-5
Engine oil and oil filter cartridge ............. 6-12
Engine stop switch................................... 3-6
EXUP system ........................................ 3-15
Main switch/steering lock .........................3-1
Maintenance and lubrication, periodic ......6-5
Maintenance, emission control system.....6-3
Maintenance, periodic ..............................6-1
Maintenance record .................................9-5
Model label ..............................................9-2
F
N
Front fork, adjusting............................... 3-11
Front fork, checking ............................... 6-35
Fuel ......................................................... 3-8
Fuel gauge .............................................. 3-5
Fuel level warning light ............................ 3-2
Fuel tank cap........................................... 3-7
Fuses, replacing .................................... 6-38
Neutral indicator light ...............................3-2
Noise regulation .......................................9-4
E
Cables, checking and lubricating............6-33
Canister (for California only)...................6-11
Carburetors, adjusting............................6-21
Care.........................................................7-1
Centerstand and sidestand,
checking and lubricating ......................6-34
Clutch lever..............................................3-6
Clutch lever free play, adjusting .............6-27
Coolant ..................................................6-15
Changing..........................................6-17
Checking ..........................................6-15
Coolant temperature warning light............3-2
H
D
Key identification number ........................ 9-1
Dimmer switch .........................................3-5
L
Handlebar switches ................................. 3-5
Headlight bulb, replacing ....................... 6-39
Helmet holder ........................................ 3-10
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-5
I
Identification numbers ............................. 9-1
Ignition circuit cut-off system.................. 3-17
Indicator and warning lights ..................... 3-2
K
O
Oil level warning light ...............................3-2
P
Panels, removing and installing................6-8
Parking.....................................................5-6
Part locations ...........................................2-1
Pre-operation check list............................4-1
S
Safety defects, reporting ..........................9-3
Safety information ....................................1-1
Seat .......................................................3-10
Self-diagnosis devices .............................3-4
Shifting.....................................................5-3
Decelerating .......................................5-4
Shift points..........................................5-5
Starting out and accelerating ..............5-4
Shift pedal................................................3-6
Shock absorber assembly, adjusting......3-13
U5LV10.book Page 2 Wednesday, October 23, 2002 2:45 PM
INDEX
Sidestand .............................................. 3-16
Spark plugs, checking ........................... 6-10
Specifications .......................................... 8-1
Speedometer unit .................................... 3-3
Starter (choke) lever ................................ 3-9
Starting and warming up a cold engine.... 5-1
Starting a warm engine............................ 5-3
Start switch.............................................. 3-6
Steering, checking ................................. 6-35
Storage.................................................... 7-4
Storage compartment ............................ 3-11
Suspension (rear), lubricating ................ 6-34
T
Tachometer unit ...................................... 3-3
Tail/brake light bulb, replacing ............... 6-41
Throttle cable free play, adjusting .......... 6-22
Tires ...................................................... 6-23
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-45
Troubleshooting charts .......................... 6-46
Turn signal indicator lights ....................... 3-2
Turn signal light bulb, replacing ............. 6-41
Turn signal switch.................................... 3-5
V
Valve clearance, adjusting..................... 6-22
Vehicle identification number ................... 9-1
W
Warranty, extended ................................. 9-9
Warranty limited....................................... 9-7
Wheel bearings, checking...................... 6-36
Wheel (front) ......................................... 6-42
Installing .......................................... 6-43
Removing ........................................ 6-42
Wheel (rear) .......................................... 6-43
Installing .......................................... 6-45
Removing ........................................ 6-43
Wheels.................................................. 6-26
OWNER’S MANUAL
FZS1000N
FZS1000NC
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2001 . 1 - 2.3 × 3 CR
(E)
LIT-11626-14-48
5LV-28199-10